Power Tool Including Depth Sensing

This application claims the benefit of U.S. Provisional Patent Application No. 63/574,344, filed on Apr. 4, 2024, the entire content of which is hereby incorporated by reference.

The present disclosure relates to power tools.

The present disclosure relates to power tools that include one or more depth sensors to determine one or more distances between a power tool and a workpiece. The present disclosure also relates to techniques for controlling power tools with such depth sensors.

In some instances, power tools described herein include a housing and a motor within the housing. The motor may include a rotor and a stator. The rotor may be coupled to a motor shaft to produce a rotational output. The power tool may also include an output drive device configured to be driven by the motor shaft to perform a task. The power tool may also include an actuator configured to be actuated by a user to cause the motor to operate. The power tool may also include a depth sensor located adjacent to the output drive device and configured to generate a distance signal. The power tool may also include an electronic controller including an electronic processor and a memory. The electronic controller may be coupled to the actuator and to the depth sensor. The electronic controller may be configured to control the motor to operate in response to determining that the actuator has been actuated. The electronic controller may also be configured to determine a first distance between the depth sensor and the workpiece by monitoring the distance signal from the depth sensor during operation of the motor. The first distance may be greater than a predetermined threshold distance upon the actuator being actuated. The electronic controller may also be configured to determine that the first distance has decreased to be less than or equal to the predetermined threshold distance. The electronic controller may also be configured to change how the motor is controlled to operate in response to determining that the first distance has decreased to be less than or equal to the predetermined threshold distance.

In addition to any combination of features described above, the predetermined threshold distance may indicate a desired fastening depth. In addition to any combination of features described above, the electronic controller may be configured to change how the motor is controlled to operate in response to determining that the first distance has decreased to be less than or equal to the predetermined threshold distance by stopping the motor.

In addition to any combination of features described above, the predetermined threshold distance may indicate a second distance away from a desired fastening depth. In addition to any combination of features described above, the electronic controller may be configured to change how the motor is controlled to operate in response to determining that the first distance has decreased to be less than or equal to the predetermined threshold distance by slowing a speed of the motor from a first speed to a second speed.

In addition to any combination of features described above, the electronic controller may be configured to determine the predetermined threshold distance by monitoring the distance signal from the depth sensor during driving of a previous fastener into the workpiece by determining a second distance between the depth sensor and the workpiece in response to the motor being deactivated upon completion of a fastening operation of the previous fastener, and setting the predetermined threshold distance based on the second distance.

In addition to any combination of features described above, the electronic controller may be configured to determine the predetermined threshold distance by determining a second distance between the depth sensor and the workpiece prior to the motor being activated and in response to a user input that indicates the power tool is located in a position to measure a desired fastening depth. In addition to any combination of features described above, the electronic controller may be configured to set the predetermined threshold distance based on the second distance.

In addition to any combination of features described above, the electronic controller may be configured to determine an initial distance between the depth sensor and the workpiece at a time that the actuator is actuated and in response to determining that the actuator has been actuated. In addition to any combination of features described above, the electronic controller may be configured to determine the predetermined threshold distance by subtracting a predetermined value from the initial distance. In addition to any combination of features described above, the electronic controller may be configured to change how the motor is controlled to operate in response to determining that the first distance has decreased to be less than or equal to the predetermined threshold distance by increasing a speed of the motor from a starting speed to a driving speed.

In addition to any combination of features described above, the predetermined threshold distance may indicate a specified depth change from an initial depth. In addition to any combination of features described above, the electronic controller may be configured to operate the motor in a pulsed manner. The electronic controller may be configured to operate the motor in the pulsed manner by disabling the motor for a predetermined period of time in response to determining that the first distance has decreased the specified depth change from the initial depth to a second depth. The electronic controller may be configured to operate the motor in the pulsed manner by determining that the actuator has remained actuated during the predetermined period of time, in response to determining that the predetermined period of time has elapsed and that the actuator has remained actuated during the predetermined period of time. The electronic controller may be configured to operate the motor in the pulsed manner by re-enabling the motor until the first distance has again decreased the specified depth change from the second depth. The electronic controller may be configured to operate the motor in the pulsed manner by disabling the motor for the predetermined period of time in response to determining that the first distance has again decreased the specified depth change from the second depth. The electronic controller may be configured to operate the motor in the pulsed manner by continuing, until the first distance reaches a desired fastening depth or until the actuator is released, operating the motor in the pulsed manner by disabling the motor for the predetermined period of time and enabling the motor after the predetermined period of time and until the first distance has again decreased the specified depth change from a depth measured during the predetermined period of time of a directly preceding instance of the motor being disabled.

In addition to any combination of features described above, power tools may include a lighting element configured to illuminate a work area of the power tool. In addition to any combination of features described above, power tools may include a circuit board located adjacent to the output drive device. In addition to any combination of features described above, the circuit board may include the lighting element and the depth sensor.

In addition to any combination of features described above, the circuit board may include a ring-like-shaped circuit board that surrounds over half of an output axis of the output drive device.

In addition to any combination of features described above, power tools may include a hammer case held by the housing. In addition to any combination of features described above, power tools may include a nose piece that covers a front portion of the hammer case. In addition to any combination of features described above, the circuit board may be mounted on an inside of a front surface of the nose piece. In addition to any combination of features described above, the nose piece may include a lens to allow light from the lighting element to be emitted through the nose piece to illuminate the work area.

In addition to any combination of features described above, the nose piece may be mounted to the hammer case by being snap fit to a retention ring that is located in a groove on an outer peripheral surface of a forwardly protruding portion of the hammer case. In addition to any combination of features described above, the nose piece may include a rearwardly extending arm that is located between protrusions on the outer peripheral surface of the hammer case to prevent the nose piece from rotating around an output axis of the output drive device.

In some instances, power tools described herein include a housing, and a motor within the housing. The motor may include a rotor and a stator. The rotor may be coupled to a motor shaft to produce a rotational output. The power tool may also include an output drive device configured to be driven by the motor shaft to perform a task. The power tool may also include an actuator configured to be actuated by a user to cause the motor to operate. The power tool may also include a depth sensor located adjacent to the output drive device and configured to generate a distance signal. The power tool may also include an electronic controller including an electronic processor and a memory. The electronic controller may be coupled to the actuator and to the depth sensor. The electronic controller may be configured to control the motor to operate in response to determining that the actuator has been actuated. The electronic controller may also be configured to determine a first distance between the depth sensor and the workpiece by monitoring the distance signal from the depth sensor during operation of the motor at a first time. The electronic controller may also be configured to determine a second distance between the depth sensor and the workpiece by monitoring the distance signal from the depth sensor during operation of the motor at a second time. The electronic controller may also be configured to determine a feed rate of the power tool based on (i) a first difference between the first distance and the second distance and (ii) a second difference between the first time and the second time.

In addition to any combination of features described above, the electronic controller may be configured to control a speed of the motor based on the feed rate to maintain the feed rate within a range of a predetermined feed rate values.

In addition to any combination of features described above, the electronic controller may be configured to determine a speed of the motor by monitoring a position signal from a position sensor associated with the motor. In addition to any combination of features described above, the electronic controller may be configured to determine an output speed of the output drive device based on the speed of the motor. In addition to any combination of features described above, the electronic controller may be configured to determine a fastener pitch of a fastener being fastened by the power tool based on the feed rate and the output speed.

In addition to any combination of features described above, the electronic controller may be configured to control, based on the fastener pitch, the feed rate to be maintained within a range of a predetermined feed rate values.

In addition to any combination of features described above, the electronic controller may be configured to determine a speed of the motor by monitoring a position signal from a position sensor associated with the motor. In addition to any combination of features described above, the electronic controller may be configured to determine that the speed of the motor has increased a first predetermined amount. In addition to any combination of features described above, the electronic controller may be configured to determine that the feed rate has decreased a second predetermined amount. In addition to any combination of features described above, the electronic controller may be configured to change how the motor is controlled to operate by stopping the motor or by slowing a speed of the motor from a first speed to a second speed in response to determining (i) that the speed of the motor has increased the first predetermined amount and (ii) that the feed rate has decreased the second predetermined amount.

In some instances, power tools described herein include a housing and a motor within the housing. The motor may include a rotor and a stator. The rotor may be coupled to a motor shaft to produce a rotational output. The power tool may also include an output drive device configured to be driven by the motor shaft to perform a task. The power tool may also include an actuator configured to be actuated by a user to cause the motor to operate. The power tool may also include a depth sensor located adjacent to the output drive device and configured to generate a distance signal. The power tool may also include a lighting element configured to illuminate a work area of the power tool. The power tool may also include a circuit board located adjacent to the output drive device. The circuit board may include the lighting element and the depth sensor. The power tool may also include a nose piece that surrounds an output axis of the output drive device. The circuit board may be mounted on an inside of a front surface of the nose piece. The nose piece may include a lens to allow light from the lighting element to be emitted through the nose piece to illuminate the work area.

In addition to any combination of features described above, the circuit board may include a ring-like-shaped circuit board that surrounds over half of the output axis of the output drive device.

In addition to any combination of features described above, power tools may include a hammer case held by the housing. The nose piece may cover a front portion of the hammer case. The nose piece may be mounted to the hammer case by being snap fit to a retention ring that is located in a groove on an outer peripheral surface of a forwardly protruding portion of the hammer case. The nose piece may include a rearwardly extending arm that is located between protrusions on the outer peripheral surface of the hammer case to prevent the nose piece from rotating around an output axis of the output drive device.

In addition to any combination of features described above, wires from inside the housing of the power tool that are coupled to the lighting element and the depth sensor may be covered by the rearwardly extending arm.

Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in application to the details of the configurations and arrangements of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

Unless the context of their usage unambiguously indicates otherwise, the articles “a,” “an,” and “the” should not be interpreted as meaning “one” or “only one.” Rather these articles should be interpreted as meaning “at least one” or “one or more.” Likewise, when the terms “the” or “said” are used to refer to a noun previously introduced by the indefinite article “a” or “an,” “the” and “said” mean “at least one” or “one or more” unless the usage unambiguously indicates otherwise.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%) of an indicated value.

It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

Accordingly, in the claims, if an apparatus, method, or system is claimed, for example, as including a controller, control unit, electronic processor, computing device, logic element, module, memory module, communication channel or network, or other element configured in a certain manner, for example, to perform multiple functions, the claim or claim element should be interpreted as meaning one or more of such elements where any one of the one or more elements is configured as claimed, for example, to make any one or more of the recited multiple functions, such that the one or more elements, as a set, perform the multiple functions collectively.

Other aspects of various embodiments will become apparent by consideration of the detailed description and accompanying drawings.

illustrates a communication system. The communication systemincludes power tool devicesand an external device. Each power tool device(e.g., battery powered impact driverand power tool battery pack) and the external devicecan communicate wirelessly while they are within a communication range of each other. Each power tool devicemay communicate power tool status, power tool operation statistics, power tool identification, stored power tool usage information, power tool maintenance data, and the like. Therefore, using the external device, a user can access stored power tool usage or power tool maintenance data. With this tool data, a user can determine how the power tool devicehas been used, whether maintenance is recommended or has been performed in the past, and identify malfunctioning components or other reasons for certain performance issues. The external devicecan also transmit data to the power tool devicefor power tool configuration, firmware updates, or to send commands (e.g., turn on a work light). The external devicealso allows a user to set operational parameters, safety parameters, select tool modes, and the like for the power tool device.

The external devicemay be, for example, a smart phone (as illustrated), a laptop computer, a tablet computer, a personal digital assistant (PDA), or another electronic device capable of communicating wirelessly with the power tool deviceand providing a user interface. The external deviceprovides the user interface and allows a user to access and interact with tool information. The external devicecan receive user inputs to determine operational parameters, enable or disable features, and the like. The user interface of the external deviceprovides an easy-to-use interface for the user to control and customize operation of the power tool.

The external deviceincludes a communication interface that is compatible with a wireless communication interface or module of the power tool device. The communication interface of the external devicemay include a wireless communication controller (e.g., a Bluetooth® module), or a similar component. The external device, therefore, grants the user access to data related to the power tool device, and provides a user interface such that the user can interact with the controller of the power tool device.

In addition, as shown in, the external devicecan also share the information obtained from the power tool devicewith a remote serverconnected by a network. The remote servermay be used to store the data obtained from the external device, provide additional functionality and services to the user, or a combination thereof. In some embodiments, storing the information on the remote serverallows a user to access the information from a plurality of different locations. In some embodiments, the remote servermay collect information from various users regarding their power tool devices and provide statistics or statistical measures to the user based on information obtained from the different power tools. For example, the remote servermay provide statistics regarding the experienced efficiency of the power tool device, typical usage of the power tool device, and other relevant characteristics and/or measures of the power tool device. The networkmay include various networking elements (routers, hubs, switches, cellular towers, wired connections, wireless connections, etc.) for connecting to, for example, the Internet, a cellular data network, a local network, or a combination thereof. In some embodiments, the power tool devicemay be configured to communicate directly with the serverthrough an additional wireless interface or with the same wireless interface that the power tool deviceuses to communicate with the external device. In some instances, the communication systemmay include more of fewer of each of the illustrated devices. For example, the communication system may include more or fewer power tool devicesand/or external devices.

The power tool deviceis configured to perform one or more specific tasks (e.g., drilling, cutting, fastening, pressing, lubricant application, sanding, heating, grinding, bending, forming, impacting, polishing, lighting, etc.). For example, an impact wrench and a drill are associated with the task of generating a rotational output (e.g., to drive a bit to drill a hole or secure a fastener to a workpiece).

illustrates an example of the power tool deviceas an impact driver. The impact driveris representative of various types of power tools that operate within the system. Accordingly, the description with respect to the impact driverin the systemis similarly applicable to other types of power tools, such as other power tools with impact mechanisms (e.g., impact wrenches and impacting angle drivers) or without impact mechanisms (e.g., power drills). As shown in, the impact driverincludes an upper main body(e.g., a motor housing), a handle, a battery pack receiving portion, an output drive device, an actuator(e.g., trigger), a work light(embodied by multiple work light elements such as light-emitting diodes [LEDs]), and forward/reverse selector. The housing of the impact driver(e.g., the main body, the handle, and the battery pack receiving portion) are composed of a durable and light-weight plastic material. The output drive deviceis composed of a metal (e.g., steel). The output drive deviceon the impact driveris a socket. However, other power tools may have a different drive devicespecifically designed for the task associated with the other power tool. The battery pack receiving portionis configured to receive and couple to the battery pack (e.g.,of) that provides power to the impact driver. The battery pack receiving portionincludes (i) a connecting structure to engage a mechanism that secures the battery pack and (ii) a terminal block to electrically connect the battery pack to the impact driver.

In some instances, the impact driverincludes a hammer caselocated at a front portion of the upper main body. The hammer casehouses an impact mechanism (not shown) that includes a hammer and an anvil. A nose piecemay cover a portion of the front and/or sides of the hammer caseto protect the hammer case. The nose piecemay also house one or more LEDsthat serve as a work light for the impact driver. For example, most of the nose piecemay be opaque but the nose piecemay include openings to receive lenses to allow the LEDsto emit light through the lenses to illuminate a work area. The nose piecemay also house one or more depth sensors(i.e., distance sensors) located adjacent to the output drive device. In some instances, the nose piecemay include additional openings to allow the depth sensorsto transmit and receive signals (e.g., sound, light, electromagnetic waves, and/or the like) to measure a distance between the depth sensorsand a workpiece as described in greater detail below. In some instances, the nose piecedoes not include the additional openings for the depth sensors. Rather, the depth sensorsmay be configured to measure a distance between the depth sensorsand a workpiece through a front surface of the nose piecewhile taking the front surface of the nose pieceinto account.

As shown in, in some instances, the impact drivermay include three lighting elements(e.g., work light LEDs) and three depth sensors. Each depth sensormay be located equidistant from each other spaced approximately 120 degrees apart around an output axisof the output drive device. Each depth sensormay be located between two LEDsat an equal distance between each of the two LEDs. In some instances, the impact drivermay include fewer or additional LEDsand/or depth sensors. In some instances, the impact drivermay include LEDsand/or depth sensorsin different arrangements. In some instances, the LEDsand depth sensorsare located on a ring-shaped or ring-like-shaped circuit board such as a printed circuit board (PCB) that is mounted on the inside of a front surface of the nose piece(see). In some instances, three separate arcuate PCBs are mounted on the inside of the front surface of the nose piece, and each PCB includes a LEDand a depth sensor. In some instances, electrical wires that provide power and/or data signals to/from the LEDsand/or depth sensorsmay run through an interior of the hammer caseback to a main housing of the impact driverto couple to a power source (e.g., a battery pack) and/or to a controller of the impact driver. Additionally or alternatively, the electrical wires may run on the outside surface of the hammer caseand may be covered by the arms/wings,shown in. In some instances, a portion of the electrical wires may run on the outside surface of the hammer caseand another portion of the electrical wires may run through the interior of the hammer case.

illustrate an example of the impact driverwith a different nose piece(i.e., a different work light and depth sensor mounting design). Like-named and like-labeled components may be similar to those described with respect to. The nose piecemay also be referred to as a cap, a cover, or a light/sensor holder. As shown in, the nose piecemay include a ring-shaped lens. In some instances, the ring-shaped lensmay alternatively be a ring-like-shaped lens (e.g., a lens that almost surrounds the output axis, for example, by 300 degrees, 330 degrees, by 180 degrees (i.e., over half of the output axisof the output drive device), or the like but that does not completely surround the output axis). As shown in the partially exploded view in, the nose piecemay include a transparent light holderB that includes the ring-shaped lens. The nose piecemay also include an opaque overmoldA (e.g., made of rubber, plastic, or the like). The transparent light holderB may include rearwardly extending wings/armsthat extend between protrusions on an outer peripheral surface of the hammer case. The overmoldA may include similar rearwardly extending wings/arms. Each arm of the overmoldA may include features(e.g., protrusions) configured to engage with corresponding features(e.g., holes/indents) (see) to secure the overmoldA to the transparent light holderB. While the overmoldA and the transparent light holderB are shown as separate components that are mounted to each other, in some instances, the overmoldA and the transparent light holderB are integrally molded together (e.g., using multi-injection molding) to form a unified piece that acts as the light/sensor holder.

The transparent light holderB is configured to receive a ring-shaped PCBin a PCB holding grooveshown in. The transparent light holderB may include one or more tabs or other mounting features to hold the PCBin place or otherwise properly locate the PCBwithin the transparent light holderB. Additionally or alternatively, epoxy and/or another adhesive may be used to secure the PCBto the transparent light holderB. In some instances, the PCBmay be ring-like-shaped or may include multiple PCBs distributed around the output axisof the impact driver. As shown in, the ring-shaped PCBmay include multiple LEDsand/or depth sensorsas described previously herein. Light may be emitted by the LEDsin a ring-like manner through the ring-shaped lensto illuminate a work area in a more shadowless manner compared to light being emitted from individual points on the nose pieceshown in. In some instances, the ring-shaped lensmay include a light conditioning feature such as a texture and/or a frosting such that light is output in a more uniform manner around the output axis.

In some instances, the nose pieceis mounted to the hammer caseby being snap fit to a retention ringthat is located in a grooveon an outer peripheral surface of a forwardly protruding portionof the hammer case(see). The grooveand the retention ringmay be generally circular in shape but may not form a full 360-degree ring. Rather, as shown in, the grooveand the retention ringmay form a circular shape of 350 degrees, 340 degrees, or the like around the output axis. The retention ringmay include outwardly protruding portions (e.g., at approximately the 3 o'clock position and the 9 o'clock position) that are configured to engage with mounting tabs(see) of the transparent light holderB of the nose piece. Accordingly, the retention ringmay be inserted into the groove, and the nose piecemay be pressed onto the front of the hammer caseuntil the mounting tabssnap fit around the protruding portions of the retention ringto secure the nose pieceto the hammer casein the front/rear direction. Because the arms,of the nose pieceare located between protrusions on the outer peripheral surface of the hammer case, the nose pieceis prevented from rotating around the output axis. As shown in, in some instances, an outer portion of a front surface of the hammer caseincludes a grooveto receive a rear edge of the nose piece. The groovemay continue onto the outward facing protrusions on the outer peripheral surface of the hammer caseto also receive the edges of the arms,of the nose piece.

Although the power tool deviceis shown as an impact tool, in some instances, the control methods described herein function on a drill or other power tool that provides a rotational output but that does not include an impact mechanism. Rather, the output drive deviceof such power tools may be coupled directly to the motor(i.e., direct drive power tools) or may be coupled to the motorvia one or more gears (e.g., a gear mechanism). For example, for some power tools, the hammer casemay instead be a gear case that houses gears instead of an impact mechanism. As another example, some power toolsmay not include a hammer caseor a gear case. Rather, the nose piecemay be coupled to a front portion of the upper main bodyand/or may be formed from/integrated with a front portion of the upper main body.

As shown in, the impact driveralso includes a motor. The motoractuates the drive deviceand allows the drive deviceto perform the particular task (e.g., provide a rotational output to drive a fastener). The motormay include a rotor and a stator. The rotor may be coupled to a motor shaft to produce a rotational output that drives the output drive devicedirectly or via one or more gears. A primary power source (e.g., a battery pack)couples to the impact driverand provides electrical power to energize the motor. The motoris energized based on the position of the trigger. When the triggeris depressed the motoris energized, and when the triggeris released, the motoris de-energized. In the illustrated embodiment, the triggerextends partially down a length of the handle. In other embodiments, the triggerextends down the entire length of the handleor may be positioned elsewhere on the impact driver. The triggeris moveably coupled to the handlesuch that the triggermoves with respect to the tool housing. The triggeris coupled to a push rod, which is engageable with a trigger switch(see). The triggermoves in a first direction towards the handlewhen the triggeris depressed by the user. The triggeris biased (e.g., with a spring) such that it moves in a second direction away from the handle, when the triggeris released by the user. When the triggeris depressed by the user, the push rod activates the trigger switch, and when the triggeris released by the user, the trigger switchis deactivated. In other embodiments, the triggeris coupled to an electrical trigger switch. In such embodiments, the trigger switchmay include, for example, a transistor. Additionally, for such electronic embodiments, the triggermay not include a push rod to activate the mechanical switch. Rather, the electrical trigger switchmay be activated by, for example, a position sensor (e.g., a Hall-Effect sensor) that relays information about the relative position of the triggerto the tool housing or electrical trigger switch. The trigger switchoutputs a signal indicative of the position of the trigger. In some instances, the signal is binary and indicates either that the triggeris depressed or released. In other instances, the signal indicates the position of the triggerwith more precision. For example, the trigger switchmay output an analog signal that varies from 0 to 5 volts depending on the extent that the triggeris depressed. For example, 0 V output indicates that the triggeris released, 1 V output indicates that the triggeris 20% depressed, 2 V output indicates that the triggeris 40% depressed, 3 V output indicates that the triggeris 60% depressed, 4 V output indicates that the triggeris 80% depressed, and 5 V indicates that the triggeris 100% depressed. The signal output by the trigger switchmay be analog or digital.

As also shown in, the impact driverincludes a switching network, sensors, indicators, the battery pack interface, a power input unit, an electronic controller, a wireless communication controller, and a back-up power source. The back-up power sourceincludes, in some embodiments, a coin cell battery or another similar small replaceable power source. The battery pack interfaceis coupled to the electronic controllerand couples to the battery pack. The battery pack interfaceincludes a combination of mechanical (e.g., the battery pack receiving portion) and electrical components configured to and operable for interfacing (e.g., mechanically, electrically, and communicatively connecting) the impact driverwith the battery pack. The battery pack interfaceis coupled to the power input unit. The battery pack interfacetransmits the power received from the battery packto the power input unit. The power input unitincludes active and/or passive components (e.g., voltage step-down controllers, voltage converters, rectifiers, filters, etc.) to regulate or control the power received through the battery pack interfaceand to the wireless communication controllerand controller.

The switching networkenables the electronic controllerto control the operation of the motor. Generally, when the triggeris depressed as indicated by an output of the trigger switch, electrical current is supplied from the battery pack interfaceto the motor, via the switching network. When the triggeris not depressed, electrical current is not supplied from the battery pack interfaceto the motor.

In response to the electronic controllerreceiving the activation signal from the trigger switch, the electronic controlleractivates the switching networkto provide power to the motor. The switching networkcontrols the amount of current available to the motorand thereby controls the speed and torque output of the motor. The switching networkmay include numerous FETs, bipolar transistors, or other types of electrical switches. For instance, the switching networkmay include a six-FET bridge that receives pulse-width modulated (PWM) signals from the electronic controllerto drive the motor.

The sensorsare coupled to the electronic controllerand communicate to the electronic controllervarious signals indicative of different parameters of the impact driveror the motor. The sensorsinclude Hall sensors, the depth sensors, among other sensors, such as, for example, one or more voltage sensors, one or more temperature sensors, and one or more torque sensors. Each Hall sensoroutputs motor feedback information to the electronic controller, such as an indication (e.g., a pulse) when a magnet of the motor's rotor rotates across the face of that Hall sensor. Based on the motor feedback information from the Hall sensors, the electronic controllercan determine the position, velocity, and acceleration of the rotor. In response to the motor feedback information and the signals from the trigger switch, the electronic controllertransmits control signals to control the switching networkto drive the motor. For instance, by selectively enabling and disabling the FETs of the switching network, power received via the battery pack interfaceis selectively applied to stator coils of the motorto cause rotation of its rotor. The motor feedback information is used by the electronic controllerto ensure proper timing of control signals to the switching networkand, in some instances, to provide closed-loop feedback to control the speed of the motorto be at a desired level.

In some instances, the depth sensor(s)emit a signal that is reflected off of a workpiece and back to the depth sensor(s)to allow the depth sensor(s) to determine a time of flight of the emitted signal, which is indicative of the distance between the depth sensor(s)and the workpiece. In some instances, the emitted signal may be a sound signal, a light signal, an electromagnetic wave, and/or the like. Based on the time of flight, the depth sensor(s)and/or the electronic controllermay determine a distance between the depth sensor(s)and the workpiece. The data provided by the depth sensor(s)to the electronic controllermay be referred to as a distance signal. In some instances, other types of depth sensorsmay be used to determine a distance between the depth sensor(s)and the workpiece and/or other objects.

The indicatorsare also coupled to the electronic controllerand receive control signals from the electronic controllerto turn on and off or otherwise convey information based on different states of the impact driver. The indicatorsinclude, for example, one or more light-emitting diodes (“LED”), or a display screen. The indicatorscan be configured to display conditions of, or information associated with, the impact driver. For example, the indicatorsare configured to indicate measured electrical characteristics of the impact driver, the status of the impact driver, the mode of the power tool (discussed below), etc. The indicatorsmay also include elements to convey information to a user through audible or tactile outputs. The work light LEDsare also controllable by the electronic controller, for example, to illuminate in response to the triggerbeing actuated.

As described above, the electronic controlleris electrically and/or communicatively connected to a variety of components of the impact driver. In some embodiments, the electronic controllerincludes a plurality of electrical and electronic components that provide power, operational control, and protection to the components within the electronic controllerand/or impact driver. For example, the electronic controllerincludes, among other things, a processing unit(e.g., a microprocessor, a microcontroller, an electronic controller, an electronic processor, or another suitable programmable device), a memory, input units, and output units. The processing unit(herein, electronic processor) includes, among other things, a control unit, an arithmetic logic unit (“ALU”), and a plurality of registers(shown as a group of registers in). In some embodiments, the electronic controlleris implemented partially or entirely on a semiconductor (e.g., a field-programmable gate array [“FPGA”] semiconductor) chip, such as a chip developed through a register transfer level (“RTL”) design process. The electronic controllermay include any one or a combination of electronic controllersand/or their components distributed within the impact driver. Thus, in the claims, if an apparatus or system is claimed, for example, as including an electronic controller or other element configured in a certain manner, for example, to make multiple determinations, the claim or claim element should be interpreted as meaning one or more electronic controllers (or other element) where any one of the one or more electronic controllers (or other element) is configured as claimed, for example, to make some or all of the multiple determinations. To reiterate, those electronic processors and processing may be distributed within impact driver.